5.2. Wiring
Connect DC cabling between the charger's BATTERY terminals and the battery/batteries or DC system distribution bus; all LEDs
will illuminate briefly when DC power is connected.
a. Ensure that the DC system is fully shut down (all DC loads and charge sources off/isolated) prior to disconnection of
any existing battery/DC system distribution bus cabling and connection of the charger to the battery terminals/DC system
distribution bus.
b. Ensure that wiring polarity is correct; use red cabling for the
+
(positive) connections and black cabling for the
-
(negative)
connections.
c. Use flexible multi stranded copper cable with sufficient cross sectional area, inline with an appropriate fuse or circuit breaker;
refer to the 'Installation - Cable and fusing' section for more information.
d. Refer to the 'Installation - Schematics' section for wiring schematic diagrams; wiring configuration for most typical installations
are shown.
Connect any required communication cabling (VE.Direct) and/or control wiring (remote on/off and/or programmable relay).
Connect the AC power cable to a mains power outlet; all LEDs will illuminate briefly when the charger is powered up, then the
LED indicating the charge state will illuminate.
5.2.1. Cable and fusing
To enable proper and safe operation it is important to select and use suitably rated DC cabling, combined with a suitably rated
inline fuse or circuit breaker.
Cable type/specification selection should consider the following aspects:
a. Use flexible multi-stranded copper cable; the diameter of each individual strand should not exceed 0.4mm (0.016 inch) or a
surface area of 0.125mm² (AWG26).
In case cable with thicker strand diameter is used the contact area will be insufficient and cause excessive resistance at the
terminations/connections, this will generate heat and subsequently result in severe overheating or a fire.
Power cable with a flexibility class of 5 or higher is recommended (according to VDE 0295, IEC 60228 and BS6360).
b. Use cable with high quality insulation; ensure that the cable voltage rating is in excess of the maximum operating voltage.
Power cable with a 0.6/1kV voltage rating is recommended.
c. Use cable with a maximum operating temperature rating of at least 90°C (194°F).
Cable gauge/cross sectional area selection should consider the following aspects:
a. The cable must have sufficient cross sectional area to safety withstand the fault current required to blow the fuse / trip the
circuit breaker (not just the maximum operating current).
b. The cable must have sufficient cross sectional area to prevent overheating when operating continuously at maximum
operating current.
c. The cable must have sufficient cross sectional area to avoid excessive voltage drop between the charger and battery, this is
related to maximum operating current and cable length.
It is recommended to size cable gauge/cross sectional area for a maximum of 2% voltage drop at maximum operating current.
Refer to the table below for the minimum recommended conductor cross sectional area (in relation to cable length) and the
recommended fuse/circuit breaker rating:
Charger model
Fuse / circuit
breaker
Conductor area <5m
Conductor area 5-10m
Phoenix Smart IP43 Charger 12/30
40 - 50A
10mm
2
8 AWG
16mm
2
6 AWG
Phoenix Smart IP43 Charger 12/50
60 - 75A
16mm
2
6 AWG
16mm
2
6 AWG
Phoenix Smart IP43 Charger 24/16
20 - 25A
6mm
2
10 AWG
10mm
2
8 AWG
Phoenix Smart IP43 Charger 24/25
30 - 40A
10mm
2
8 AWG
16mm
2
6 AWG
Phoenix Smart IP43 Charger
Page 15
Installation
